Rosemount BINOS 100 M Analyzer-2nd Ed. Owner's manual

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

Operation Manual

2. Edition 11/97

Catalog - No: 90 002 953

BINOS

®

100 M

Microprocessor - Controlled

NDIR - / Oxygen - Analyzer

BINOS

®

100

Microprocessor - Controlled

NDIR - Analyzer

Managing The Process Better

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

Read this operation manual carefully before attempting to operate the analyzer !

For expedient handling of reports of defects, please include the model and serial number which

can be read on the instrument identity plate.

Look for the error check list please too (see Item 29. of this manual)

Fisher-Rosemount GmbH & Co assumes no liability for any omissions or errors in this manual.

Any liability for direct or indirect damages, which might occur in connection with the delivery or the use of

this manual, is expressly excluded to the extend permitted by applicable law.

This instrument has left the works in good order according to safety regulations.

To maintain this operating condition, the user must strictly follow the instructions and consider the warnings

in this manual or provided on the instrument.

Troubleshooting, component replacement and internal adjustments must be made by qualified

service personnel only.

According to the report No. “IBS/PFG-No. 41300392” about the approval of “DMT - Gesellschaft für

Forschung und Prüfung mbh, Fachstelle für Sicherheit - Prüfstelle für Grubenbewetterung”, the stationary

gas analyzer BINOS

®

100 is suitable for measuring the concentrations of methane between 0 and 80 %

CH

4

and of carbon dioxide between 0 and 80 % CO

2

. The system control with serial interfaces as described

in this operation manual have not been subject to the DMT-approval. The DMT-investigation has no validity

for BINOS

®

100 M (combined NDIR / Oxygen measurement).

According to the report No. 95CU054/B about the approval of “TÜV Nord mbH” the gas analyzer BINOS

®

100(M) is suitable for CO measuring according to TI Air and 13. BlmSchV (large furnaces order) and for

O

2

measuring according to TI Air, 13

th

BlmSchV (large furnaces order) and 17

th

BlmSchV (incineration).

Misprints and alterations reserved

©

1996-97 by FISHER-ROSEMOUNT GmbH & Co. (RAE)

1. Edition: 09/96

2. Edition: 11/97

Fisher - Rosemount GmbH & Co.

Industriestrasse 1

D - 63594 Hasselroth

Phone + 49 60 55 / 884 - 0

Telefax + 49 60 55 / 884 - 209

CONTENTS

I

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

CONTENTS

INTRODUCTION E - 1

SAFETY SUMMARY S - 1

General S - 1

Gases and Gas Conditionning (Sample Handling) S - 2

Supply Voltage S - 3

Connection Cables S - 3

Electrostatic Discharge S - 4

Operating Conditions according to DMT - Approval S - 5

TECHNICAL DESCRIPTION

1. Setup 1 - 1

1.1 Front Panel 1 - 1

1.2 Rear Panel 1 - 1

1.3 Inside View 1 - 2

2. Photometer Assembly 2 - 1

2.1 Photometer with Pyroelectrical Detector 2 - 1

2.2 Photometer with Gas Detector 2 - 4

3. Measuring Principle 3 - 1

3.1 IR - Measurement 3 - 1

3.1.1 Interference Filter Correlation (IFC Principle) 3 - 1

3.1.2 Opto - Pneumatic Measuring Principle 3 - 3

3.1.3 Technique 3 - 5

3.2 Oxygen Measurement (Electrochemical Principle) 3 - 6

4. Main Features 4 - 1

CONTENTS

II

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

OPERATION

5. Preparation 5 - 1

5.1 Installation 5 - 1

5.2 Gas Conditionning (Sample Handling) 5 - 2

5.2.1 Gas Flow Rate 5 - 2

5.3 Gas Connections 5 - 3

6. Switching On 6 - 1

6.1 Battery Operation 6 - 1

6.2 Power Supply Operation 6 - 2

7. Key Functions 7 - 1

7.1 FUNCTION 7 - 2

7.2 ENTER 7 - 3

7.3 INPUT - CONTROL 7 - 5

8. Entry of System Parameters 8 - 1

8.1 Pressure Correction 8 - 2

8.2 Cross - Compensation 8 - 2

8.3 Cross - Compensation Calibration 8 - 3

8.4 Hold 8 - 4

8.5 Automatic Calibration 8 - 4

8.6 Tolerance Check 8 - 5

8.7 Display Off 8 - 6

8.8 Analog Signal Outputs 8 - 6

8.9 Flushing Period 8 - 8

8.10 User Code 8 - 8

8.11 Response Time (t

90

) 8 - 9

8.12 Offset (Begin of range) 8 - 10

8.13 End of Range Value 8 - 11

8.14 Reset 8 - 12

8.15 Program Version 8 - 13

8.16 Serial - No. 8 - 13

8.17 Copy - No. 8 - 13

8.18 Absorber 8 - 14

CONTENTS

III

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

9. Calibration 9 - 1

9.1 Manual Calibration 9 - 2

9.1.1 Zeroing 9 - 2

9.1.2 Spanning 9 - 4

9.2 Automatic Calibration Mode (Option) 9 - 7

9.2.1 Zeroing 9 - 7

9.2.2 Combined Zeroing and Spanning 9 - 9

10. Digital Outputs 10 - 1

10.1 Concentration Limits 10 - 2

10.2 Valve Control 10 - 4

10.3 Status Signals (Option) 10 - 4

11. Measurement / Switching Off 11 - 1

11.1 Measurement 11 - 1

11.2 Switching Off 11 - 2

12. Serial Interface (Option) 12 - 1

12.1 Retrofitting of Serial Interface / Status Signals 12 - 1

12.2 General 12 - 2

12.3 Start Up 12 - 4

12.3.1 RS 232 C 12 - 5

12.3.2 RS 485 12 - 5

12.3.3 Switching ON/OFF Interface Operation 12 - 6

12.3.4 Setting Interface Parameters 12 - 6

12.4 Telegram Syntax 12 - 8

12.4.1 Start Character ( “$” = Hex 24) 12 - 8

12.4.2 Terminate Character ( “CR” = Hex OD) 12 - 8

12.4.3 Instruction Code 12 - 8

12.4.4 Hyphen Character ( “;” = Hex 3B) 12 - 8

12.4.5 Status Telegram 12 - 9

12.4.6 Numerical Representations 12 - 10

12.4.7 Block Parity Check 12 - 10

12.5 Instruction Syntax 12 - 11

12.5.1 Instruction Listing 12 - 12

12.5.2 Response Telegrams 12 - 13

CONTENTS

IV

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

TROUBLESHOOTING

13. Error List 13 - 1

14. Measuring Points of BKS and OXS 14 - 1

14.1 Measuring points of BKS 14 - 1

14.1.1 Supply Voltage + 6 V 14 - 1

14.1.2 Reference Voltage positive 14 - 1

14.1.3 Reference Voltage negative 14 - 2

14.1.4 Motor Drive 14 - 2

14.1.5 Temperature Sensor 14 - 3

14.1.6 Light Barrier Signal 14 - 3

14.1.7 Analog Preamplifiering 14 - 4

14.2 Measuring points of OXS (oxygen measurement) 14 - 5

14.2.1 Sensor Signal 14 - 5

15. Plug Pin Allocation of BKS and OXS 15 - 1

15.1 Plug Pin Allocation of BKS 15 - 1

15.1.1 BINOS® 100 (IR - measurement without oxygen channel) 15 - 2

15.1.2 BINOS® 100 M (IR - / Oxygen Measurement combined) 15 - 2

15.2 Plug Pin Allocation OXS (oxygen measurement only) 15 - 2

16. Jumper Allocation of BKS 16 - 1

17. Open

CONTENTS

V

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

MAINTENANCE 18 - 1

19. Open

20. Leak Testing 20 - 1

21. Opening of the Housing 21 - 1

22. Replacement and Cleaning of Photometric Components 22 - 1

22.1 Removal of the Photometer Assembly 22 - 1

22.2 Light Source Replacement 22 - 2

22.3 Cleaning of Analysis Cells and Windows 22 - 3

22.3.1 Removal of Analysis Cells 22 - 3

22.3.2 Cleaning 22 - 4

22.3.3 Reinstalling of Analysis Cells 22 - 5

22.4 Reinstalling of the Photometer Assembly 22 - 6

22.5 Physical Zeroing 22 - 7

22.5.1 Standard - Photometer (not sealed version) 22 - 7

22.5.2 Sealed Photometer (Option) 22 - 8

23. Check and Replacement of the Oxygen Sensor 23 - 1

23.1 Check of the Sensor 23 - 2

23.2 Replacement of the Sensor 23 - 3

23.2.1 Removal of the Sensor 23 - 3

23.2.2 Exchange of the Sensor 23 - 4

23.2.3 Reinstalling of the Sensor 23 - 4

23.2.4 Basic conditions for the Oxygen Sensor 23 - 5

CONTENTS

VI

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

TECHNICAL DATA 24 - 1

24.1 Voltage Supply 24 - 4

24.1.1 Electrical Safety 24 - 4

24.1.2 Power Supply 24 - 4

SUPPLEMENT

25. Replacing the EPROM 25 - 1

26. Pin - Assignments 26 - 1

27. Connection Cable 27 - 1

28. Open

29. Failure Check List 29 - 1

INDEX R - 1

List of Figures R - 7

INTRODUCTION

E - 1

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

Introduction

The BINOS

®

100 gas analyzer is a member of the 100 series of our gas analyzers program. It is

designed for the continuous monitoring of gas concentrations and uses infrared absorption for its

operation.

The BINOS

®

100 M analyzer includes both, one infrared channel and one electrochemical

channel for oxygen measurement.

The compactness of the BINOS

®

100 (M) permits its use in a wide variety of applications in industry

and research. Energy conservation, occupational safety, and quality assurance are the major

areas addressed.

Some typical specific applications are:

❏ Flue gas analyses for combustion efficiency in firing systems, gas cleaning systems

and legislation compliance (CO / CO

2

or CO / O

2

)

❏ Analysing landfill gas for ex protection (CH

4

/ CO

2

, CO

2

/ O

2

, CH

4

/ O

2

combinations)

❏ Monitoring metallurgical processes in metals refining and processing (CO / CO

2

/ HC)

❏ Quality monitoring of natural gas (CO

2

)

❏ Monitoring fermentation and sewages processes in biotechnology (CO

2

)

❏ Motor vehicle exhaust gas analyses (Internal Combustion Engine Emissions)

❏ Air quality monitoring [vehicular tunnel, gas production, personal protection (CO / CO

2

/ HC)]

❏ Food industry

❏ Universities and Research Institutes

INTRODUCTION

E - 2

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

The analyzers of the BINOS

®

100 (M) series are complete, ready - to - use, gas analyzers which

may be directly inserted into existing or planned gas lines.

Since BINOS

®

100 (M) is working according to the extractive measuring method an adequate

sample handling system has to be provided.

The analyzer is microprocessor controlled.

Programming available with use of optional, external solenoid valves permit fully automatic

calibration of the analyzer.

All inputs required may be activated by a host computer via an optional serial interface

(RS 232 C / 485), for networking applications.

Note:

Read this operation manual carefully before attempting to operate the analyzer !

For single - channel analyzers:

The display, entries and error messages for the second channel described

in this manual are inapplicable.

SAFETY SUMMARY

S - 1

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

Safety Summary

In this manual we have used the following safety symbols

to draw your attention to strictly follow these instructions !

1. General

◆ The following general safety precautions must be observed during all phases of operation,

service and repair of this instrument !

Failure to comply with these precautions or with specific warnings elsewhere in this manual

violates safety standards of design, manufacture and intended use of this instrument !

Failure to comply with these precautions may lead to personal injury and damage to this

instrument !

◆ Fisher-Rosemount GmbH & Co. assume no liability for the customer´s failure to comply with

these requirements !

◆ Do not attempt internal service or adjustment unless other person, capable of rendering first

aid and resuscitation, is present !

◆ Because of the danger of introducing additional hazards, do not perform any unauthorized

modification to the instrument !

Return the instrument to a Fisher-Rosemount Sales and Service office for service or repair

to ensure that safety features are maintained !

◆ Operating personnel must not remove instrument covers !

Component replacement and internal adjustments must be made by qualified service

personnel only !

◆ Instruments which appear damaged or defective should be made inoperative and secured

against unintended operation until they can be repaired by qualified service personnel.

GENERAL

SAFETY SUMMARY

S - 2

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

GENERAL / GASES AND GAS CONNECTIONS

Read this operation manual carefully before attempting to operate with the

instrument !

Do not operate the instrument in the presence of flammable gases, explosive

atmosphere or furnes without supplementary protective measures !

The installation site for the instrument has to be dry and remain above freezing

point at all times.

The instrument must be exposed neither to direct sunlight nor to strong sources

of heat. Be sure to observe the permissible ambient temperature !

For outdoor sites, we recommend to install the instrument in a protective cabinet.

At least, the instrument has to be protected against rain (e.g., shelter).

Due to the high temperatures of photometer or heated components there is a

danger of burns to the operators.

2. Gases and Gas Conditionning (Sample Handling)

Do not interchange gas inlets and gas outlets !

All gases have to be supplied to the system as conditionned gases !

When the instrument is used with corrosive gases, it is to be verified that there

are no gas components which may damage the gas path components.

The exhaust gas lines have to be mounted in a declining, descending,

pressureless and frost-free and according to the valid emission legislation !

Be sure to observe the safety regulations for the respective gases

(sample gas and test gases / span gases) and the gas bottles !

Inflammable or explosive gas mixtures must not be purged into the instrument

without supplementary protective measures !

To avoid a danger to the operators by explosive, toxic or unhealthy gas

components, first purge the gas lines with ambient air or nitrogen (N

2

) before

cleaning or exchange parts of the gas paths.

SAFETY SUMMARY

S - 3

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

3. Supply Voltage

◆ Verify correct polarity for 24 V DC - operation !

◆ This product is a Safety Class 1 instrument (provided with a protective earth terminal).

To prevent shock hazard, the instrument chassis and cabinet must be connected to an

electrical ground. The instrument must be connected to the AC power supply mains through

a three-conductor power cable, with the third wire firmly connected to an electrical ground

(safety ground) at the power outlet. If the instrument is to be energized via an external power

supply, that goes for the power supply too.

Any interruption of the protective (grounding) conductor or disconnection of the protective

earth terminal will cause a potential shock hazard that could result in personal injury.

Deliberate disconnection is inadmissible / prohibited !

◆ Use only power supply VSE 2000 or equivalent power supplys to be in agreement with the

CE - conformity.

◆ In case of exchanging fuses the customer has to be certain that fuses of specified type and

rated current are used. It is prohibited to use repaired fuses or defective fuse holders or to

short-circuit fuse carriers (fire hazard).

◆ Always disconnect power, discharge circuits and remove external voltage sources before

troubleshooting, repair or replacement of any component !

Any work inside the instrument without switching off the power must be

performed by a specialist, who is familiar with the related danger, only !

4. Connection Cables

◆ Use only from our factory optional delivered cables or equivalent shielded cables to be in

agreement with the CE - conformity.

The customer has to guarantee, that the shield is be connected bothsided.

◆ By using of optional delivering terminal strip adapters the analyzer is not be in agreement

with the CE - conformity. In this case CE - conformity is to be declared by customer as

“manufacturer of system”.

SUPPLY VOLTAGE

SAFETY SUMMARY

S - 4

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

5. Electrostatic Discharge

The electronic parts of the analyzer can be irreparably damaged if exposed to electrostatic

discharge (ESD).

The instrument is ESD protected when the covers have been secured and safety precautions

observed. When the housing is open, the internal components are not ESD protected anymore.

Although the electronic parts are reasonably safe to handle, you should be aware of the following

considerations:

Best ESD example is when you walked across a carpet and then touched an electrically grounded

metal doorknob. The tiny spark which has jumped is the result of electrostatic discharge (ESD).

You prevent ESD by doing the following:

Remove the charge from your body before opening the housing and maintain during work with

opened housing, that no electrostatic charge can be built up.

Ideally you are opening the housing and working at an ESD - protecting workstation.

Here you can wear a wrist trap.

However, if you do not have such a workstation, be sure to do the following procedure exactly:

Discharge the electric charge from your body. Do this by touching a device that is electrically

grounded (any device that has a three - prong plug is electrically grounded when it is plugged into

a power receptacle).

This should be done several times during the operation with opened housing (especially after

leaving the service site because the movement on a low conducting floors or in the air might cause

additional ESDs).

ELECTROSTATIC DISCHARGE

SAFETY SUMMARY

S - 5

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

6. Operating Conditions according to DMT - Approval

(Chapter 6 of the supplement I to the DMT - report No. “IBS/PFG-No. 41300392” about the

performance test of the stationary gas analyzer BINOS

®

100.

According to the system version and measuring results included in this report, the stationary gas

analyzer BINOS

®

100 from Rosemount GmbH & Co. is suitable for measuring the concentrations

of methane between 0 and 80 % CH

4

and of carbon dioxide between 0 and 80 % CO

2

, if the features

and system version go conform with the details contained in the enclosed documents as stated

in this report, if the analysis system is operated accordingly and if the following requirements are

met:

◆ When using the gas warning system, it must be ensured that the permissible variations will

not be exceeded, taking into account the systematics failures of the measuring signals (as

indicated in this report) and the local operating conditions. Consider the Code of Pratice No.

T032 of the Labor Association of the Chemical Industry "Usage of stationary gas warning

systems for explosion protection".

◆ Verify that the explosion protection requirements are met when using the gas warning

system.

◆ Depending on the situation, it must be verified that the preset values are low enough to allow

the system to activate the necessary protection and emergency measures and, thus, to

prevent any critical situations in a minimum period of time.

◆ When at system installation, a release of one or both measuring components in the ambient

air might occur, its influence on the measuring result should be proved. A sealed cell or an

external housing purging with sample-free air of measuring gases can be used, if required.

◆ The operatability of the alarms and the displays of each system should be tested with clean

air and test gas after the initial operation, after each long-time interruption, and periodically.

The tightness of gas pathes should also be tested. The tests must be documented by

keeping accounts.

OPERATING CONDITIONS ACCORDING TO DMT - APPROVAL

SAFETY SUMMARY

S - 6

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

◆ The intervals for the periodical tests must be settled by the person being responsible for the

system´s security and in accordance with the Code of Pratice No. T023 of the Labor

Association of the Chemical Industry "Maintenance of stationary gas warning systems for

explosion protection".

◆ Consider the superproportional dependency of the barometric pressure on the measured

value for CO

2

.

◆ The system control with serial interfaces described in this operation manual have not been

subject to this investigation.

◆ Sample gas condensation in analyzer (components) must be prevented by taking the

necessary steps.

◆ When the system is used with aggressive gases, it is to be verified that there are no gas

components which might damage the gas path components.

◆ Appropriate dust filters must precede the used systems.

◆ The pressure and flow values recommended by the manufacturer should be observed. An

external monitoring of the sample gas flow through the analyzer should be provided.

◆ The results of this investigation are based on the systems using software versions "3.03" and

"4.00" and "4.01". A change of the software version used must be certified by the Testing

Association.

◆ It should be ensured that the system parameters for the analog output have been correctly

adjusted. End of range of low concentration should not be identical or lower than the begin

of range. Disregarding these versions, the measurement range should be adjusted between

0 to 80 % CH

4

and 0 to 80 % CO

2

when the systems are used for explosion protection.

◆ Read and follow the operation and maintenance manual supplied to and certified by PFG.

It is important that the temperature is kept between 5 and 45 °C.

OPERATING CONDITIONS ACCORDING TO DMT - APPROVAL

SAFETY SUMMARY

S - 7

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

◆ The analyzer housings must be provided with a permanent type plate indicating the name

of the manufacturer, model number, serial number, and the following reference and date of

testing:

"IBS/PFG-Nr. 41300392"

Other designation requirements, such as these according to ElexV, are still valid. With this

type plate, the manufacturer conformes that the features and technical data of the delivered

system are identical with those described in this report. Any system which is not provided

with such a type plate does not go conform with this report.

◆ The chapter 6 of this report must be included in the operation and maintenance manual.

◆ The manufacturer has to supply the customer with a copy of this report, if required.

◆ A print of the report in an abridged version requires the agreement of PFG.

◆ The results included in this report may not be altered in publications produced by the

manufacturer.

OPERATING CONDITIONS ACCORDING TO DMT - APPROVAL

SAFETY SUMMARY

S - 8

90002953(1) BINOS

®

100(M) e [4.01] 25.09.96

1 - 1

SETUP

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

1. Setup

The analyzer it incorporated in a 1/4 19" rack-mounting housing, 3 height units.

The optional table-top housing is fitted with a carrying strap and rubber feets additional.

1.1 Front Panel

The front panel (see Fig. A-1) includes the LED - displays and all of the analyzer operating controls.

1.2 Rear Panel

The rear panel (Fig. A-2) includes

❏ the gas line fittings

❏ the plug for the electrical supply input

❏ the sub-miniature “D” mating socket for the analog signal outputs

❏ the sub-miniature “D” plug for the digital outputs (concentration limits and valve control)

❏ optionally the sub-miniature “D” mating socket for the RS 232 C / 485 - interface

❏ optionally the sub-miniature “D” plug for the status signals (relay outputs)

FRONT PANEL

1 - 2

SETUP

90002953(2) BINOS

®

100(M) e [4.10] 19.11.97

REAR PANEL

1.3 Inside View

The inside view is shown in Fig. 1-1 and Fig 1-2.

❏ Depending of analyzer

- one IR - photometer

- two IR - Photometer

- one O

2

- sensor (electrochemical) and one IR - Photometer

{no DMT - certification)

- one pressure sensor (optional)

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Rosemount BINOS 100 M Analyzer-2nd Ed. Owner's manual

Rosemount BINOS 100 M Analyzer-2nd Ed. Owner's manual

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